System and method for continuous strand fiberglass media processing
There is provided a system and method for manufacturing continuous strand fiberglass of progressive density with varying skins. Glass media is melted into molten glass within a temperature controlled melter, the molten glass exits the melter through orifices of a bushing plate, which is oriented 6 degrees relative to the axis of a rotating drum. A rotating drum receives the molten glass exiting the bushing plate, and resin and water are applied. The fiberglass media is fed through rollers before it enters a curing oven.
1. A method of manufacturing fiberglass media comprising:
providing glass into a melter and through a bushing plate to produce continuous glass filament strands;
repeatedly traversing the melter above a rotating drum in a first direction along a substantial length of the rotating drum and an opposite second direction along the substantial length of the rotating drum;
depositing the continuous glass filament strands onto the rotating drum;
spraying resin onto the continuous glass filament strands on the rotating drum to form a fiberglass mat;
removing the fiberglass mat from the rotating drum;
providing the fiberglass mat through a roller apparatus comprising an upper roller and a lower roller;
applying a liquid consisting of water to the fiberglass mat; and
immediately after applying the liquid to the fiberglass mat, curing the fiberglass mat in a curing oven.
2. The method of claim 1 , comprising: orienting the bushing plate at a 6-degree angle relative to the first direction.
3. The method of claim 1 , comprising: cooling, via a cooling loop assembly, the continuous glass filament strands.
4. The method of claim 1 , comprising: spraying the resin onto a swath of the continuous glass filament strands deposited onto the rotating drum.
5. The method of claim 4 , comprising: spraying the resin in a width of between 4 inches and the width of the swath.
6. The method of claim 1 , comprising: spraying water onto a swath of the continuous glass filament strands deposited onto the rotating drum.
7. The method of claim 6 , comprising:
spraying the resin in a width of between 4 inches and the width of the swath;
spraying the water in a width of between 4 inches and the width of the swath.
8. The method of claim 1 , wherein the roller apparatus comprises bowed rollers.
9. The method of claim 1 , comprising: expanding the fiberglass mat before curing the fiberglass mat in the curing oven.
10. The method of claim 1 , comprising: providing the fiberglass mat onto a let-off table assembly.
11. The method of claim 10 , comprising:
applying heat to a first side of the fiberglass mat via a first heat source; and
applying heat to a second side of the fiberglass mat via a second heat source.
12. The method of claim 1 , comprising:
curing the fiberglass mat in a first chamber of the curing oven at a first temperature; and
curing the fiberglass mat in a second chamber of the curing oven at a second temperature, wherein the first temperature and the second temperature are not equal.
13. The method of claim 12 , comprising:
setting a height between an upper conveyor chain and a lower conveyor chain within the curing oven; and
providing the fiberglass mat between the upper conveyor chain and the lower conveyor chain.
14. The method of claim 13 , comprising: moving the upper conveyor chain at a different speed than the lower conveyor chain.
15. The method of claim 1 , comprising: removing the fiberglass mat from the curing oven and providing the fiberglass mat to accumulator rollers.
16. The method of claim 1 , comprising: weighing the fiberglass mat after removing the fiberglass mat from the rotating drum.
17. The method of claim 1 , comprising: controlling the temperature of the resin to within 10% of 70 degrees Fahrenheit.
18. A method of manufacturing fiberglass media comprising:
providing glass into a melter and through a bushing plate to produce continuous glass filament strands;
repeatedly traversing the melter above a rotating drum in a first direction along a substantial length of the rotating drum and an opposite second direction along the substantial length of the rotating drum;
cooling, via a cooling loop assembly, the continuous glass filament strands;
depositing the continuous glass filament strands onto the rotating drum;
spraying resin onto the continuous glass filament strands on the rotating drum to form a fiberglass mat;
removing the fiberglass mat from the rotating drum;
providing the fiberglass mat onto a let-off table assembly;
applying heat to a first side of the fiberglass mat via a first heat source;
applying heat to a second side of the fiberglass mat via a second heat source;
providing the fiberglass mat through a roller apparatus comprising an upper roller and a lower roller;
applying a liquid consisting of water to the fiberglass mat; and
immediately after applying the liquid to the fiberglass mat, curing the fiberglass mat in a curing oven.
19. The method of claim 18 , comprising:
curing the fiberglass mat in a first chamber of the curing oven at a first temperature; and
curing the fiberglass mat in a second chamber of the curing oven at a second temperature, wherein the first temperature and the second temperature are not equal.
20. The method of claim 18 , comprising:
setting a height between an upper conveyor chain and a lower conveyor chain within the curing oven; and
providing the fiberglass mat between the upper conveyor chain and the lower conveyor chain; and
moving the upper conveyor chain at a different speed than the lower conveyor chain.